Custom Lighting Extrusion Tooling
Profile design, tooling design, mould machining, trial extrusion and profile adjustment – the stage that decides whether a section runs clean in production.
Tooling is where a profile succeeds or fails
Two sections can look identical on a drawing and behave completely differently on the line. Material flows to the thickest part of a section, thin walls cool faster than thick ones, and internal corners concentrate stress. A die that ignores these produces a profile that bows, twists or holds no tolerance – however good the drawing was.
Because we design and machine tooling ourselves, trial results feed straight back into die adjustments instead of into a round of emails with a third party.
Tooling sequence
- Profile design – the section is finalised for extrusion, not just for drawing
- Tooling design – die geometry designed around material flow and cooling
- Mould machining – die and calibration tooling machined in-house
- Trial extrusion – first run to see how the section actually behaves
- Profile adjustment – die refined until section, tolerance and surface are right
- Production tooling – released for volume runs once samples are approved
Adjustment is normal, not a failure. Expect at least one trial-and-adjust cycle on a new section; complex optical profiles can need more. We build that into the schedule rather than treating it as a surprise.
What tooling has to solve
- Uniform wall thickness so the section cools evenly and holds shape
- Material flow balanced so thin sections fill and thick sections do not sag
- Calibration and cooling matched to the section, not to a generic setting
- Optical surfaces - prism and lens geometry - held along the full length
- Straightness and twist controlled for long linear runs
- Surface finish free of flow lines, die marks and chill marks
Frequently Asked Questions
Tooling made for your profile is your project tooling. We confirm ownership terms in the quotation so there is no ambiguity later.
Yes – adjustment is a normal part of development. Trial extrusion shows where the section needs correction, and the die is refined before production release.
It depends on section complexity. We quote tooling lead time with the quotation rather than giving a generic figure.
If you have existing tooling, we can assess it and advise whether it can be run or modified on our lines.
Send us your drawing or sample
Our engineers review geometry, material and tooling feasibility and come back with a profile proposal and quotation.
Or email your drawing to info@leddiffuserfactory.com · WhatsApp +37259205909 · WeChat +861587897761